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Procedia CIRP 40 (2016) 568 – 573

13th Global Conference on Sustainable Manufacturing - Decoupling Growth from Resource Use

Sustainable Machining of Metal Matrix Composites Using Liquid Nitrogen

Sravan Kumar Josyulaa, Suresh Kumar Reddy Naralab*, E.Guru Charana, H. A. Kishawyb
a
BITS Pilani Hyderabad Campus, Hyderabad, 500078, India
b
University of Ontario Institute of Technology, Oshawa, L1H 7K4, Canada
* Corresponding author. Tel.: +9140-66303565; fax: +9140-66303998. E-mail address: nskreddy@hyderbad.bits-pilani.ac.in

Abstract

Machining of composite materials is difficult due to the high abrasiveness of reinforcing constituents. This creates friction between work piece-
tool-chip interfaces resulting in high temperatures. The risk of developing elevated temperatures can be controlled by coolants, however, they are
known to cause environmental problems. In the interest of ecological and environmental safety the global focus is towards achieving sustainable
manufacturing. In the present study, a pressurized liquid nitrogen (LN2) feeding system is developed to supply LN2 over the tool edge-work piece
interface. Comparative experiments are carried out during cutting of Al-5%TiCP under cryogenically chilled air (CCA), LN2, wet and dry
conditions. It is found that LN2 reduces surface roughness, tool wear and cutting temperatures. Further, there is a reduction in built up edge
formation. LN2 assisted machining has shown to improve machinability of composites while achieving sustainable manufacturing.
©© 2016
2016 The
TheAuthors.
Authors. Published
Published by
by Elsevier
Elsevier B.V.
B.V.This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing.
Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing
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1. Introduction characteristics of these MMCs and thus influences

Metal matrix composites (MMC) play a vital role in modern
material science in all types of engineering and structural
applications. Striving continuously to improve production
methods and finding alternative materials are the best solution
to meet the requirements of MMC in aerospace, marine,
defense, automotive and medical fields. Aluminum metal
matrix composites (AMC) have greater advantages in a wide
number of specific fields because of its superior properties,
especially high specific modulus (modulus per unit weight) and
specific strength (strength per unit weight) [1].
Several ceramic reinforcements are identified for AMCs,
but titanium carbide (TiC) has gained attention due to its high
hardness, high specific strength, stiffness, wear resistance and
dimensional stability [2]. Discontinuously TiC particulate
reinforced aluminum composites (DRAC)-(Al-TiCP)
composite usually are produced close to the final dimension in
different manufacturing methods but in most engineering
applications, the need for machining cannot be completely
eliminated to get the final dimensions. The existence of hard
particles in soft metal matrix increases the mechanical
machinability using conventional methods such as turning,
drilling, milling and sawing [3].
The machining of DRAC presents significant challenges to
industries due to the high abrasiveness of the reinforcing
particles and the anisotropic & non homogenous structure.
Premature failure of tool is reported as the major problem in
machining of DRAC [4]. This creates friction between
workpiece-cutting tool-chip interfaces leading to high
temperature. This can cause poor surface finish, higher cutting
forces and built up edge on the cutting tool.
Conventional coolants have been used as supplementary
choice in order to overcome these problems. However,
incompatibilities have been reported in relation to conventional
coolants in machining of composite materials. Hung et al., [5]
studied the effect of cutting fluid on the machinability of AMC
reinforced with SiC or Al2O3 particles, observed that cutting
fluid had no significant effect on machining performance in
terms of tool life, surface finish and cutting forces.
Comparative studies for dry and wet turning of DRAC were
investigated by Kannan et al. [6]. They reported that small
differences were observed between the cutting forces in dry and

2212-8271 © 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing
doi:10.1016/j.procir.2016.01.135
 Sravan Kumar Josyula et al. / Procedia CIRP 40 (2016) 568 – 573
wet cutting conditions. This result was attributed to the rapid
abrasion of the cutting tool (coated tungsten carbide) by the
particles even under wet cutting conditions suggesting the
incapability of the cutting fluid to create any protective film
which would reduce the frictional conditions on the tool flank
face. Due to effective cooling, prominent results were
witnessed at higher cutting speeds (240 m/min) in terms of
cutting forces and reduced tool flank wear. Under wet cutting
conditions, surface quality was found to have deteriorated by
using coolant. Also the micro-hardness of the machined surface
increased. In another study Shetty et al., [7] examined the
machining performance of DRAC under steam, oil oblique
water emulsion and dry conditions. It was inferred that high
pressure steam improves the turning performance of DRAC
composites in terms of cutting force and cutting temperature
reductions. From these studies it can be clearly understood that
conventional coolants fail to provide desirable cutting
temperature in the cutting zone.
Global focus is towards achieving sustainable
manufacturing, in the interest of ecological and environmental
safety. Liquid nitrogen (LN2) is an ecofriendly coolant and
lubricant used for the desirable control of cutting temperature
and enhancement of the tool life [8]. It also reduces power
consumption and friction force, improves dimensional
accuracy, surface quality, chip breakability and chip removal
for precision machining [9]. Further, it reduces manufacturing
cost and manufacturing time by providing machining with
higher cutting speeds [10]. Different cryogenic machining
strategies such as 1) Cryogenic pre-cooling the workpiece/tool
2) Indirect cryogenic cooling 3) Cryogenic spraying and jet
cooling (by delivering the cryogen to the tool-chip or tool/work
interfaces) have been applied to the cutting operations.
In all of the three strategies, the cooling effect is observed
to be the cryogenic spray and jet cooling strategies, however
have shown both cooling effect as well as lubrication effect.
Studies by Hong et al., [11] studies reveal that LN2 possesses
lubrication effect. A fluid cushion was formed by LN2 at the
tool-chip interface and provided a lubrication effect by
absorbing heat and evaporating quickly. Thus the feed force
decreased at cold temperatures because of the lower friction
between the chip and tool face. This lower friction can be
achieved by reducing the cutting temperature and micro scale
hydrostatic effect. In order to maximize the hydrostatic effect
LN2 should be applied as close as possible to the contact area
with high pressure [12].
Singh et al., [13] used cryogenic spray method for
improving the grindability of ceramic matrix composites. It
was observed that that there is an improvement in surface
quality of the ground surface with cryogenic cooling because
of lubrication effect of cryogenic mist at grinding zone under
high pressure application of the cryogen. It was also stated that
specific grinding energy was reduced by cryogenic cooling,
depending on the reduction in cutting forces.
In the past few decades, numerous studies have been carried
out on cryogenic machining. However, machinability studies in
cryogenic machining of MMCs are very limited. Further
effective supply of liquid nitrogen into the chip-tool interface
has shown to improve the machining performance. The main
objective of this study is to develop a supply system to apply
569
LN2 exactly on the machining interface based upon a new
concept of having a high lubricity despite of penetration of
LN2. In this research work, turning experiments on Al-5%TiCP
composites are carried out under LN2 as coolant and lubricant.
Tool wear and surface roughness are the two important
performance characteristics considered in this work.
Comparative studies are carried out to analyze the effectiveness
of LN2 with dry, wet and cryogenically chilled air (CCA). The
experimental results indicate that the new method can be
applied to industry for improving operation environment and
lowering manufacturing costs.
2. Experimentation
Machining studies were carried out on Al-5%TiCP
composite fabricated by stir casting process under inert
atmosphere. The chemical composition of matrix material,
reinforcement properties are given in Table 1. 5% TiC particles
were preheated at 300oC and introduced into molten metal in
the form of capsules during mechanical stirring. A blanket of
argon gas was maintained to prevent reaction of molten
aluminum with atmosphere. After addition of TiC particles, a
15 min nonstop stirring produced a homogenous mixture. This
mixture of molten metal was poured into a mold to form test
material in bars. These bars were fully heat treated to the T71
condition before carrying out the cutting experiments.
Table 1. Work material details
Titanium carbide (TiC): Source: Himedia labs Pvt Ltd
Density: 4900 Kgm-3
Average particle size: -325 mesh size
(40microns)
Aluminium (Al): Commercially pure aluminum
composition (by weight %) Si, 0.15; Fe,
0.15; Cu, 0.021; Ti, 0.053; Mg, 0.92;
Mn, 0.044; Zn, 0.072; Cr, 0.005; Al
remaining
Workpiece material: Al-5%TiCP composite
Manufacturing method: Stir casting (argon gas as blanket)
Dimension of work piece: 30 mm diameter×150 mm length
2.1. Liquid nitrogen supply system
Fig. 1. Schematic view of LN2 supply system
LN2 supply system was developed in which the jet flow
parameters (pressure and flow rate) and cooling distance were
570 Sravan Kumar Josyula et al. / Procedia CIRP 40 (2016) 568 – 573

adjustable. A schematic design of LN2 supply system is shown
in Fig.1. The experimental setup consists of cryogenic tank,
compressor, a servo valve, pneumatic pressure gauge, solenoid
valve, and a specially designed L shaped nozzle (shown in
fig.2), LN2 pressure regulator, and rotameter for LN2 flow rate
measurement.
machined surface. The flank wear was measured using tool
makers microscope (Olympus STM6). The temperature under
all machining conditions around the chip at the cutting zone
was monitored using thermal IR imaging camera which was
positioned 350mm from the top of the cutting tool.
3. Results and discussion

In this research work, comparative studies on tool life and

Fig. 2. Photographic and schematic arrangement of nozzle outlet on the insert.
surface roughness were carried out under LN2, CCA, wet and
dry cutting conditions. In this section, the effect of cutting
environments on surface roughness, tool life, and cutting
temperature is discussed. Further, detailed explanation about
microscopic observations performed on flank wear are
presented to understand the wear mechanism of cutting
environments.

Table 2. Details of cutting tool & Machining condition
Tool geometry
Tool holder and its
common angles
approach angles ψ
(degree)
Cutting insert
Rake angles γ (degree)
Nose radius re (mm)
Process parameters
Cutting speed vs (m/min)
Feed rate f (mm/rev)
Depth of cut ap (mm)
Environment
Coolant distance (mm)
3.1 Surface roughness
P type tool holder in k20 grade
(20×20×125); Inclination angle: -60,
orthogonal rake angle: -60, orthogonal
clearance angle: 60
900
PVD Coated carbide insert of
CNMG1204 in grade of KCU10
0, 4, 8, 12, 16
0.4
250
0.3
0.5
Dry, Wet, CCA, & LN2
10

2.2 Cutting experiments

Turning experiments were performed on Al-5%TiCP
composite using coated carbide insert. The selected machining
parameters, and ISO codes of cutting insert and tool holder are
shown in Table 2. Machining process were carried out on PTC
200 lathe under dry, wet, CCA and LN2 conditions. LN2 was
supplied on the rake face of the tool tip at 2 bar pressure and
0.2 lit/min flow rate. Machinability characteristics of tool work
material was judged by work surface integrity and tool
performance.
In the present work, surface roughness was studied to
analyses the surface integrity of the machined surface. At the
same time, flank wear was measured to analyses and study the
performance of tool. Machining test was carried at the
condition as mentioned in Table 2 for a period of 2 min and all
the trials were repeated thrice at each condition in order to keep
experimental error at a minimum. The average of three
measurements was used to represent the performance of
machining. The surface roughness was measured immediately
after the turning process at five different locations on the
workpiece by using a Surface Profilometer (Taylor Hobson
Surtronic S25). Microstructure was analyzed by means of
metallurgical microscope on a section perpendicular to the
surface of work piece to observe the topography of the
Fig. 3. Surface roughness measured during machining Al-5%TiCP at various
environments.
The variation in average surface roughness (Ra) as a
function of rake angle during turning of Al-5%TiCP is shown
in Fig. 3. It is observed that as rake angle increases surface
roughness value increases due to increase in contact area
between tool and work piece. Also, it can be seen that under
LN2 lubrication the surface roughness values dropped down
significantly by a range of 21-33%, 18-27% and 8-17% in
comparison with dry, wet, and CCA at different rake angles.
This variation is observed due to supply of LN2 at high pressure
by the nozzle into the cutting zone. The pressurized LN2
penetrates effectively into tool-workpiece interface and forms
micro hydrostatic lubrication effect [11], thereby remarkably
reducing the surface roughness.
The typical surface topography of machined MMCs through
microscopic images under dry, wet and cryogenic environment
respectively are shown in Fig. 4. Micro-cracks and voids are
observed around the TiC particles due to strain hardening of
material and pull-out of TiC particles are formed due to in
cohesion between the matrix and reinforcement particles.
These intermittent particles are dragged or rolled along the
cutting zone causing scratches and grooves thereby
 Sravan Kumar Josyula et al. / Procedia CIRP 40 (2016) 568 – 573
significantly affecting the quality as well as the rate of
production [14]. This could be the reason why more grooves
result upon dry machining when compared with CCA and LN2.
LN2 condition gives more cleaned surface than CCA. This
supports the surface roughness value discussed earlier
a b c effect as LN2 but the fluidization effect varies. Pressurized
Fig. 4. Microscopic images of surface topography of machined composite at
0o rake angle under dry, wet and cryogenic condition.
3.2 Tool wear
During machining of MMCs, tool wear is not only intensive
but also irregular due to the presence of hard reinforced
particles in the matrix this further causes premature failure of
tool. The primary wear mechanism of the tools was abrasion
wear of the tool face by the reinforcement particles, with the
greatest wear on the flank face of the tool. Two body and three-
body abrasion causes flank wear between the tool and work
piece [17]. This occurs due to softening of matrix and easy
removal of particles at high cutting temperature. Therefore,
change in contact area and proper lubrication strategies will
directly influence cutting temperature and frictional generated.
This study is an attempt to investigate the effect of LN2 cutting
fluid on flank wear while turning of Al-5%TiCP composite.
Fig. 5. Microscopic observations of flack wear and BUE cutting tool after
machining of Al-5%TiCP at 8o rake angle. (a) Dry (b) Wet (c) CCA (d) LN2
Fig. 5 shows the microscopic view of flank wear while
machining of DRAC under dry, wet, and CCA and LN2
conditions. The worn tool surface is almost similar in dry &
wet condition with two body wear mechanism. But to some
extent the three body abrasion has been reduced during turning
under CCA and LN2 conditions. This can be explained in terms
of the absence of cracks and pits that the particulates indent on
the cutting tool surface. This can be attributed to the effective
application of the cutting fluid which helps in flushing away
the chips and abrasive powder formed as a result of broken
particulates. This also prevents the re-cutting of the abrasive
chips by the tool. Further, it is also observed that the built up
571
The variation in average flank wear (Vb) as a function rake
angle during turning of Al-5%TiCP is shown in Fig. 6. It is
observed that as rake angle increases, flank wear value
increases due to variation in contact area between workpiece-
tool interfaces. Under LN2 lubrication conditions the maximum
wear values reduced by about 28-48%, 15-47% and 12-42%
when comparing with dry, wet cutting, and CCA at various rake
angles. This is occurred due to significant reduction in
temperature under CCA and LN2 than dry and wet condition.
Further, recent studies have revealed that LN2 acts as lubricant
under high pressure. This might be a reason for low flank wear
in LN2 than CCA condition. CCA provides the same cooling
liquid state LN2 breaches the space between tool and work
piece due to its effective evaporation rate and creates a cushion
effect which reduces wear. Similar trend has been seen in one
of the previous work [12], where higher pressure LN 2, enters
effectively into interface zone and results in relatively lower
frictional forces, leading to lower cutting temperature.
Fig. 6. Flank wear measured under various rake angle while turning under
various lubrication strategies
3.3 Cutting temperature
The cutting temperature was measured using Thermal
Infrared Camera (sensitivity < 0.05) this camera cannot
measure the exact temperature of the cutting zone under
the cutting fluid but only measure the surface temperature
only. By considering only the surface temperature, Fig 7 shows
the variation of surface temperature as a function of rake angle
under dry, CCA and LN2 conditions. In general, LN2 mainly
depends upon heat convention to reduce cutting temperature
significantly. Further, LN2 forms a fluidized cushion between
the mating faces which helps to reduce the contact friction of
tool chip interface with high efficiency lubrication action
thereby producing a cooling effect [12]. As it is seen from
Fig.8, when LN2 is used as coolant and lubricant, the cutting
temperature reduced by range of 70-76%, 39-45% and 23-27%,
compared with dry, wet and CCA assisted machining at
different rake angles. In Fig 8, sample thermal images have
been depicted for 4 different conditions.
572 Sravan Kumar Josyula et al. / Procedia CIRP 40 (2016) 568 – 573
Fig. 7. Cutting temperature with respective rake angle while turning of
Al-5%TiCP under different lubrication strategies.
Fig. 8. Sample thermal image while turning of Al-5%TiCP under (a) Dry (b)
Wet (c) CCA (d) LN2.
3.4 Chip formation
The form of chip produced in a machining process is one of
the most important parameter, not only influences the surface
finish, but also the accuracy of workpiece and the tool life,
thereby affecting productivity and product quality [18]. Hence,
in metal cutting process, production of an acceptable form of
chip is vital. According to ISO 3685 standard, chip shapes
during a machining process can be classified into several types,
which can be in either acceptable form or unacceptable form.
Acceptable chip forms (short tubular, washer type, spiral and
arc shape) can move easily from the machining zone and do not
interfere with the machined surface quality. Contrarily,
unacceptable chips (ribbon, tangled and needle type) can not
only influence the quality of the machined surface but also tend
to pose safety problems to the operator, as they tend to tangle
around the tool and the workpiece. Figure 9 shows some of the
chip shapes obtained during machining of composite under
different cutting conditions. It is clear that the chip shapes
formed during LN2 assisted machining of Al-5%TiCP
composite are in the form tubular and helical chips are formed.
Fig. 9. Comparison of chip samples formed during machining of Al-5%TiCP
at various environments.
The cutting of Al-5%TiCP composites result in different
types of chip formation. When the tool cutting edge cuts only
the matrix but not the reinforcement particles, plastic
deformation occurs. If the shear deformation of the matrix is
hindered by reinforcing particles, squeeze-break and collapse
cutting will occur [19].
Fig. 10. Microscopic image of chip surface formed during machining of Al-
5%TiCp under LN2 condition at different rake angle. (a) 0o (b) 4 o (c) 8 o (d)
12 o (e) 16 o.
It is observed that tubular type chips are formed at 8 o&16o
rake angles while washer type helical chips are found at 0 o&
12o rake angles under all environments. In LN2 condition,
however, comparatively shorter chips are formed. At 4 o rake
angle, snarled type of chips are formed which are tangled to the
workpiece and cause surface damage. This observation
provides the proof for sudden increase in surface roughness
value in the earlier section. Microscopic observation of chip
formed reveals that cracks and voids were frequently formed
 Sravan Kumar Josyula et al. / Procedia CIRP 40 (2016) 568 – 573
on outer surface of the chip. This is due to the matrix material
undergoing shear by the movement of cutting. Once the
material was sheared, the amalgamation of voids forms cracks
and they propagate in a zig-zag manner along the shear plane
throughout the thickness of the chip. Segmented chips are
formed due to fracture. Propagation of fracture through the
matrix material seems to develop along the stress concentration
zone, i.e. at the boundary of the TiC particles with in the matrix.
In comparison among various conditions, LN2 chips found to
be more brittle and chip break occurs more easily than other
conditions (refer Fig. 10).
4. Conclusions
The performance of LN2 assisted machining process during
turning of Al-5%TiCP composite has been demonstrated
successfully. LN2 machining endow machinability of MMC
when compared with dry, wet and CCA. LN2 assisted
machining demonstrates the benefits in curtailing the heat
generation at tool-workmaterial contacts. Further, it also
improves the production of short chip of the same shape as
other environments.
Average flank wear in LN2 assisted machining reduced on
average by 36%, 20% and 12% respectively for that of dry,
wet and CCA. There was gradual reduction in BUE formation
with LN2 as coolant in turning of Al-5%TiCP composites. This
is because of the significantly lower temperature achieved by
LN2 which causes reduction in thermal softening of matrix.
This in turn reduces the adhering tendency, makes BUE spare,
decreases chip fracture and improves surface quality. Surface
quality was improved by 17%, 10% and 8% respectively
corresponding to dry, wet and CCA.
The results also suggest that the rake angle directly
influences the temperature on the tool-chip interface which in
turn effects the surface quality and tool life. It was observed
that as rake angle increases cutting temperature decreases
under all environments (dry, wet CCA and LN2). Since the chip
flow is directed by rake angle, using an optimum rake angle, all
the following factors can be controlled i.e. flow of chip, tool tip
temperature, tool life and surface quality of workpiece. Further,
it is also concluded that optimum rake angle for machining of
Al-5%TiCP composite material is γ=80. It would be clearly
viewed that rake angle of 80 gives better surface finish (Ra =
0.42 μm), lower tool wear (vb= 56.618 μm) and a close
observation on the chip flow shown that, it yields short and
continuous tubular chip formation under LN2 assisted
machining.
LN2 as a coolant and lubricant has the added advantages of
being harmless and ecofriendly. No need for disposal and
recycling makes it a lubricant of choice for machining
processes. LN2 provides the fundamental theory for green
cutting and is the future of sustainable machining.
Acknowledgment
The work has been carried out under the financial support of
the Natural Sciences and Engineering Research Council of
Canada (NSERC).
573
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